Joule
Volume 2, Issue 2, 21 February 2018, Pages 349-365
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Article
A General Framework for the Evaluation of Direct Nonoxidative Methane Conversion Strategies

https://doi.org/10.1016/j.joule.2018.01.001Get rights and content
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Highlights

  • A framework for the analysis of natural gas conversion strategies is proposed

  • A general systems-level model is developed and economic feasibility is assessed

  • Coke formation appears to be the major technical bottleneck

  • Methane one-pass conversion and ethylene selectivity are the major economic drivers

Context & Scale

Natural gas is a versatile and relatively clean chemical feedstock. The development of natural gas conversion technologies has recently received significant attention due to the increase of natural gas supply in the United States and low natural gas prices relative to crude oil. The conversion of natural gas into chemicals presents a promising means of utilizing an abundant resource while achieving energy security and mitigating pollutant emissions. Yet the direct conversion of methane to olefins is still at the basic research level, and it is unclear which of, and to what extent, these technologies must be improved to develop a commercial process. Toward this goal, we develop a simple yet flexible framework that allows for the systematic evaluation of various process alternatives and the identification of the key technology gaps.

Summary

In this paper, we study single-step natural gas conversion technologies that directly convert methane to olefins and higher hydrocarbons. Despite the relative simplicity of these technologies, the development of processes based on these approaches remains challenging. Accordingly, we utilize process synthesis and modeling to assess the economic feasibility of direct nonoxidative methane conversion strategies. We develop a flexible approach that allows for the systematic evaluation of various technology alternatives and for the identification of the key technology gaps that must be overcome. The results of our analyses demonstrate that an economically feasible direct methane conversion process is contingent upon fundamental research advances in the area of catalytic conversion to increase methane conversion to hydrocarbon products (e.g., coke formation less than 20% and a minimum conversion to products of 25%). Upon this development, further efforts can be devoted to improve ethylene selectivity as well as reduce catalyst cost and overall capital costs.

Keywords

process systems engineering
process synthesis and analysis
techno-economic analysis
natural gas
natural gas to chemicals
olefins
aromatics
hydrogen

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